Accelerating automotive test development may 2008
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Discover how Virtual Instrumentation (LabVIEW and Modular I/O) accelerates Automotive Test development.
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Accelerating automotive test development may 2008
- 1. Virtual Instrumentation – Accelerating Automotive Test Development“Developing Complex Systems Faster and Cheaper” Thorsten Mayer National Instruments
- 2. National Instruments Leaders in Computer-Based Measurement and Automation, headquartered in Austin, TX USA Long-term Track Record of Growth and Profitability Fortune’s 100 Best Companies to Work for Ninth Consecutive Year 16% of revenue invested in R&D Dr. Truchard and Jeff Kodosky inducted into Electronic Design Hall of Fame for their pioneering work in virtual instrumentation More than 4,700 employees ( > 2000 engineers) worldwide in over 40 countries (>1000 employees in Eastern Europe) $ 740M record revenue in 2007 Net Revenue in Millions
- 5. Fiat
- 7. Ferrari
- 8. Skoda
- 9. Suzuki
- 10. Valeo
- 11. Volvo…to name a few
- 13. PC Based Automotive Steering Gear Test Rig
- 14. Field Trial & Application Trial Kits for GDU and Glow Plug
- 15. Tire Unbalance Test System
- 16. Networked Test System For Braking Components
- 17. Automated Fuel Injection Pump Test Stand
- 18. Inspection of Automobile Spark Plugs
- 19. Weiss Cold Chamber Monitoring & Brake Test System
- 20. CAR Body Shell Stress test
- 21. ECU validation and End-Of-Line test
- 22. Automated Vision System for Electronic Automotive Cluster
- 23. Starter Motor Durability Test Stand
- 24. Car Window Regulators Testing System
- 25. Hardware in The Loop…to name a few
- 26. Vehicle Production Capacity – Eastern Europe “Cheap car trend pushes development to Central Eastern Europe” EE Times Europe, 28 March 2008
- 27. Automotive Technology Timeline Telescope Shock Absorber Mechanics Steel Car Body 4 Wheel Hydraulic Brakes Independent Suspension Electric Starter Power Steering Flashing Turn Signals Air Conditioning Electronics 1900 1910 1920 1930 1940 Assembly Line Mass Produced Front Drive Mass Production AT Power Steering MacPherson Strut Carburetor Drum Brakes Mechanics Electronics Continuously Variable Transmission Mass Production HEV Sensors Cruise Control Emissions Control Electronic Fuel Injection Antilock Brakes Telematics Air Bags Fuel Efficiency ECU Software/Microprocessor 1950 1960 1970 1980 1990 Traction Control Alt Fuel Keyless Entry Gasoline Direct Injection Variable Valve Timing Mass Production Disc Brakes Regenerative Braking Widely used Catalytic Converter Production Turbo Charge TPMS Power Locks Mechatronics and Algorithm Engineering Adaptive Cruise Control Commercially Available Automatic Parking Commercially Available Fuel Cell PHEV HCCI 2000 2010 2020 2030 2040
- 28. Automobiles Then and Now… Mechanics and hydraulics 3 ECUs AM/FM radio Relay-control units CAN Electromechanics 15 to 80 ECUs Telematics (Infotainment) Power-control units CAN, FlexRay, MOST, IDB ... ABI Research: „40% of the car will be electronics by 2010 !“
- 29. …Software Defines The Functionality Great benefits but also a few challenges… Car Radio
- 30. P a r a l l e l Technology Evolution
- 31. Testing Becomes More Difficult Navigation Cellular Phone CD+RW PC/WWW/ Email Automotive Telematics TV Games DVD+RW Remote Diagnostics AM/FM Stereo Satellite Car Alarm/Radio
- 32. Function Generator Programmable Switch Oscilloscope Communications Analyzer Pattern Generator Logic Analyzer DMM Power Supply LCR Meter Spectrum Analyzer A Traditional Approach Does Not Scale Anymore Automotive Telematics
- 33. Test Development Accelerators Abstraction – Fast Development Reconfiguration – Fast Adaptation Integration – Fast Assessment
- 35. Test Development Accelerators Abstraction – Fast Development Reconfiguration – Fast Adaptation Integration – Fast Assessment
- 36. Increasing Levels of Software Abstraction System design platform C# C++ Abstraction C Assembly language Machine code System complexity
- 37. LabVIEW Graphical Programming Compiled graphical development environment Development time reduction of four to ten times Tools to acquire, analyze, and present your data
- 38. Speed Development with Graphical Programming LabVIEW C* C* LabVIEW * does not include code to generate UI
- 39. Abstractions – Leveraging Latest Technology Trends
- 40. Multicore has Arrived “Intel pledges 80 cores in five years” - Paul Otellini, Intel CEO Intel Developer Forum,September 2006 19
- 41. Impact on Engineers and Scientists You must create multithreaded applications to maximize benefit from multicore processors. Measurement or Control Application Data Acquisition UserInterface Network Comm. Logging THREAD THREAD THREAD THREAD Operating System CPU Core CPU Core CPU Core CPU Core 20
- 42. Example: Text-Based Multithreading void ThreadTwo( void *){ for ( int i = 0; i < 10000; i++) { // Request ownership of the critical section EnterCriticalSection(&g_criticalSection); // Access the shared resource g_iResult += 1; // Release ownership of the critical section LeaveCriticalSection(&g_criticalSection); } // Finished g_bThreadTwoFinished = true; _endthread();} int main(){ // Initialize the critical section InitializeCriticalSection(&g_criticalSection); // Start the threads _beginthread(ThreadOne, 0, NULL); _beginthread(ThreadTwo, 0, NULL); // Wait for the threads to finish while (( false == g_bThreadOneFinished) || ( false == g_bThreadTwoFinished)) { Sleep(1); } // Release resources used by the critical section DeleteCriticalSection(&g_criticalSection); // Print the result printf("Result: %i", g_iResult); #include <windows.h> #include <stdio.h> #include <conio.h> // CriticalSection.cpp #include <windows.h>#include <stdio.h>#include <process.h> CRITICAL_SECTION g_criticalSection;bool g_bThreadOneFinished = false;bool g_bThreadTwoFinished = false;int g_iResult = 0; void ThreadOne( void *){ for ( int i = 0; i < 10000; i++) { // Request ownership of the critical section EnterCriticalSection(&g_criticalSection); // Access the shared resource g_iResult += 1; // Release ownership of the critical section LeaveCriticalSection(&g_criticalSection); } // Finished g_bThreadOneFinished = true; _endthread();} }
- 45. Now acquire and analyze 80+ channels on a multicore system“There was no need to rewrite our application for the new multicore processing platforms.” Scott Sirine Lead Design Engineer Eaton Truck Division 23
- 46. Abstraction – Enabling Technologies F E AB CD Z Y W X Graphically Programming for FPGAs VHDL F = {(A+B)CD} E
- 48. High performance
- 49. Truly parallel
- 50. Flexible
- 51. Reliable
- 53. Test Development Accelerators Abstraction – Fast Development Reconfiguration – Fast Adaptation Integration – Fast Assessment
- 54. Function Generator Programmable Switch Oscilloscope Communications Analyzer Pattern Generator Logic Analyzer DMM Power Supply LCR Meter Spectrum Analyzer Today’s Challenges: The Traditional Approach Automotive Telematics
- 57. Small size
- 58. High throughput
- 60. LabVIEW Everywhere Plug-in Devices Traditional Instruments
- 61. Accelerating Platform - Test: PXI PXIe-8130 Intel Dual Core PXI Express Bus R Series PXI DAQ 3M Gate FPGA Modular Instruments Windows or RT OS LabVIEW Sound & Vibration Toolkit, Vision Module … NI-DAQmx, NI-DMM, NI-Scope…
- 62. NI PXI – Engine Test Simulator MicroNovaUses LabVIEW FPGA for Exact and Comprehensive Engine Simulation to test the engine ECU in a BMW 12-cyclinder hydrogen-based series car Intel-based PC running Windows Ethernet Engine signals Engine Control Unit (ECU) Intel-based PXI System running Real-Time Operating System (Simulates a BMW)
- 63. PXI Multimedia & Telematics ATE System Averna, Inc. Power consumption tests I/O tests Parametric tests Vision and display tests GPS tests Cell phone tests Multimedia tests Bluetooth tests Automotive amplifier tests Satellite receiver tests
- 64. Accelerating Platform - Control: CompactRIO FPGA Point-to-Point FPGA Data Links C Series Parallel I/O LabVIEW Real-Time Thread-Safe Libraries Multithreaded RT OS LabVIEW FPGA 34
- 65. CompactioRIO – Full Authority Engine Control “In past projects, we spent at least two man-years and $500,000 to develop similar ECU prototyping systems from custom designed hardware. For this project, the equipment costs, including the motorcycle and CompactRIO, were $15,000. In addition, we spent about three man-months on this project.” – Carroll G. Dase, President of Drivven, Inc. http://www.drivven.com/
- 66. CompactRIO - In-Vehicle Datalogger Application: Vehicle Datalogger Portable, rugged and extremely versatile Onboard analysis and diagnostics Easily and single-handedly navigate all device functions In-vehicle, laboratory, environmental chamber, wind tunnel, endurance, calibration/diagnostics Platform: CompactRIO Software: LabVIEW, Real-Time and FPGA
- 67. Abstraction – Fast Development Reconfiguration – Fast Adaptation Integration – Fast Assessment Test Development Accelerators
- 68. Verification/ Validation Manufacturing and Deployment Design and Simulation Research/ Modeling Physical World Virtual World The Future Of Virtual Instrumentation
- 69. A Typical Design Cycle Manufacturing and Deployment Board and Silicon Prototype Design and Simulation Theory and Research Cost of Finding a Bug Virtual World Physical World
- 70. Test Refines Simulation and Validation Road Load Data Flow RLD Measurements Courtesy of DaimlerChrysler, General Motors, and MSC Software.
- 71. High-Level Design Models C Code Dataflow Textual Math Simulation Statechart LabVIEW Graphical System Design Platform FPGA Desktop Microprocessors Real-Time
- 72. I/O I/O I/O Processor FPGA PXI RIO Custom I/O CompactRIO Integrated The Deployment Curve PCI RIO System Flexibility and Price CompactRIO Modular LabVIEW Number of Systems Deployed
- 73. Manufacturing and Deployment Research/ Modeling Making Test Integral to the Design Cycle Virtual Instrumentation – Accelerating Automotive Test Development Design, Prototype, and Test
- 74. Software Defined Test Systems
Notas do Editor
- 2 minutesBefore we move on to general trends in Automotive engineering; a quick look at the some automotive trends in Eastern Europe (mentioned the country and replace slide accordingly)…Explain Car production trendVW just opened a new manufacturing plant Refer to article in EE Times about More design validation is moving to Eastern EuropeR&D centers have opened (BOSCH)Moreover, in a distribute world – integration of remote facilities into the process is an important topic…Both, Design validation and manufacturing are test intensive; To ensure the design will actually function the way it was intended to function & to provide solid feedback to the actual design teams;to ensure great user experience and reduce the amount of “after-service” necessary to fix problems that could have discovered during the end-of-line test. TRANSITION: So let’s take a look at global Automotive Trends…
- 1974 Honda Civic CVCCIn 1970, the U.S. passed the Clean Air Act of 1970, which set the scene for emissions standards and emissions control equipment such as the catalytic converter. In Japan Soichiro Honda of Honda Motor Co. introduced the CVCC stratified-charge engine, which not only met the U.S. emission standards without a catalytic converter but also met the stringent Japanese emission standards. In 1975 Honda exported the Honda Civic CVCC 1500 to the U.S. The four-door vehicle had a wheelbase of 2280 mm (90 in) with a front track of 1300 mm (51 in) and rear track of 1280 mm (50 in). It had a curb weight of 730 kg (1610 lb). The engine was an inline four cylinder mounted transversely with a 15° incline forward. The 1.5-L engine had a bore of 74 mm (2.91 in), stroke of 86.6 m (3.41 in), and a compression ratio of 8.1:1. Five main bearings supported the one-piece forged crankshaft. A single belt drove the overhead camshaft that operated three valves per cylinder. In the stratified-charge engine there was a tiny auxiliary chamber atop the main combustion chamber. Thus there is one valve for the auxiliary chamber and one for the intake and exhaust for a total of three valves per cylinder.Mechatronics is the new term that pulls it all together…now you don’t have to be good a mechanics which you have to understand how electronics interfaces with mechanics and guess what you’ll have to program something too.
- How hard can this be?How complex can it be? Here is a very simple example, This example code is using 2 threads to access some shared memory. Firstly, its difficult to pick out where the two threads begin and end. You cannot quickly view what is happening in parallel as the text is itself sequential by nature.
- And another application using the PXI parallel platform.Deep inside Eaton Corp. is a team of developers whose sole mission is to refine the test and measurement systems used in the company’s truck R&D division. This case study explains how this team harnessed the performance of new multi-core Intel® processors and the multithreaded architecture of National Instruments LabVIEW* graphical programming software to more than quadruple the number of channels running through their systems and achieve real-time determinism.They got there using standard, off-the-shelf desktop systems, keeping power consumption, thermal output, and – most importantly – costs, down. The move to Intel’s multi-core processors also enabled Eaton to put their system in a mobile platform so that testing can be done in the vehicle instead of in dynamometers for more accurate, efficient performance feedback.
- Unfortunately, in many companies the test process has not changed much. When the first version of the product is design one uses a traditional approach of building a prototype and making measurements…the late we find bugs in the design process the more expensive it is to fix them. You can only imagine what this means with products getting more and more complex and with the market pressure to design them faster and faster….The worst case is really when you have to do validation and design debugging on the manufacturing floor with manufacturing test equipment.